Sensor, controller and system

ABSTRACT

The present invention relates to a sensor for measuring temperature of a fluid within a vessel, the vessel having a first region and a second region and the fluid having a temperature profile extending between the first region and the second region, the sensor comprising an array of elements, each element having a temperature-dependent parameter, the array being capable of deployment within or adjacent the vessel such that the array extends along the vessel for measuring the temperature profile, the elements of the array being coupled together between an input and an output, the input being coupled or capable of being coupled to a driving source for driving the sensors, and the output being coupled or capable of being coupled to a detector for measuring an aggregate of the temperature-dependent parameter from the array of elements. The invention further relates to a fluid temperature controller comprising a first input for receiving a first signal indicating a measurement of an aggregate of a temperature-dependent parameter from a sensor deployed within or adjacent a vessel containing a fluid having a temperature profile, a second input for receiving a second signal indicating a (preferably absolute) temperature of the fluid in the vessel and a processor configured to calculate a total thermal energy of the fluid in the vessel based on the first and second signals. The invention also relates to a combination comprising a sensing arrangement and a controller; a device; and a system.

PRIORITY CLAIM TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 14/649,898, filedSep. 3, 2015, which is a U.S. national stage application filed under 35U.S.C. § 371 from International Application Serial No.PCT/GB2013/053208, which was filed 4 Dec. 2013, and published as WO2014/087162 on 12 Jun. 2014, and which claims priority to United KingdomApplication No. GB1221828.5, filed 4 Dec. 2012, which applications andpublication are incorporated by reference as if reproduced herein andmade a part hereof in their entirety, and the benefit of priority ofeach of which is claimed herein.

The present invention relates to a sensor for measuring temperature of afluid within a vessel, as well as to a related fluid temperaturecontroller and system. In particular, the invention relates to a sensingand control arrangement for a liquid or gas heating or cooling system.The sensing arrangement is used to determine volumes of heatingfluid/coolant at or above/below a predetermined useful temperature. Thecontroller may refer changes to thermal inputs or outputs based on theoutput of the sensor and determined useful volume of fluid.

There are numerous instances where a volume of fluid is stored forheating applications with end-use temperature requirements such asdomestic hot water provision, space heating or cleaning. In many suchapplications it is useful to know how much thermal energy there is alongwith the associated temperature distribution. In the case of domestichot water, knowing the temperature distribution throughout the verticalextent of the reservoir enables one to compute the useful volume offluid according to Equation 1,

$\begin{matrix}{{V_{useful} = {\int_{y{(T_{thresh})}}^{h}{{{A(y)}\left\lbrack {1 + \frac{{T(y)} - T_{thres}}{T_{thresh} - T_{c}}} \right\rbrack}dy}}},} & (1)\end{matrix}$

where V_(useful) is the volume of mixed fluid from a mixed outlet, A isthe horizontal cross-sectional area of the fluid storage vesselcontaining a stratified body of fluid some of which exists at atemperature above T_(thresh) beneath which the fluid is too cold fordirect use, for example as a hot water source. T(y) is the temperaturedistribution along a (typically horizontal) y-axis within the vesselwith height h. The temperature of the fluid at an inlet of the vessel isdenoted by T_(c). The mixed fluid is delivered from a mixing valve whichtakes a flow of fluid from a cold inlet and hot outlet. The temperaturedistribution needs to be measured for the purposes of the abovecalculation. The threshold temperature, T_(thresh), may often beassociated with the thermocline within a stratified body of fluid. Athermocline is an abrupt temperature gradient in a body of water, thelayer above having a different temperature from the layer below. Theposition of the thermocline can be used to infer the quantity ofavailable hot water, in the case of the hot water forming a distinct toplayer. The thermocline can be used to determine the useful potentialassociated with a quantity of thermal energy.

Cooling with heat exchange temperature requirements, such as coldstorage, is often used in refrigeration and air-conditioningapplications. A vessel containing chilled brine may be used in anindustrial process which requires removal of waste heat. Within astratified vessel of cold fluid, such as brine, the useful or coolingpotential of fluid, defined as the volume of coolant,V_(useful(cooling)) or waste heat brought to a threshold temperature, isexpressed by Equation 2,

$\begin{matrix}{{V_{{useful}\mspace{14mu} {({cooling})}} = {\int_{y = 0}^{y{(T_{thresh})}}{{A\left\lbrack \frac{{T(y)} - T_{thresh}}{T_{thresh} - T_{h}} \right\rbrack}{dy}}}},} & (2)\end{matrix}$

where T_(thresh) refers to the desired temperature below which is wasterheat in the system, T(y) is the temperature distribution throughout thestored coolant, A is the cross-sectional area of the vessel and T_(h) isthe initial temperature of the fluid to be cooled. Equation 2 applies toa vessel of water stored above the transition temperature associatedwith a change in correlation between water density and temperature for aparticular operating pressure, typically 2-6° C., or more preferably3-5° C., at 0.25-2 bar, or more preferably at 0.75-1.25 bars.

Knowing the useful heating or cooling volume can enable determination ofthe approximate position of the thermocline within the vessel. Where atank contains hot water for potable or bathing applications,temperatures beneath the lowest heating point are often insufficient toensure full sterilisation of human pathogens such as Pseudomonas,Legionella, E. Coli, etc. This situation arises due to the fact thatconductive heat transfer through water in a tank is significantly slowerthan the rate of convective heat transfer that arises above an immersionelement or heat exchanger. Since this leads to a portion of water withina tank that may host pathogens, a risk arises to the user whenever thetank is drained past the thermocline position (for example the showergoing cold when the hot water runs out) as the user may then be exposedto unsanitary water. A system which monitors the position of thethermocline can therefore make the user aware of both the availablevolume of hot water along with the risk of exposure to unsanitary water.Furthermore, such a system can intervene to minimise such risks byensuring that the distance between the hot water tank outlet andthermocline is kept above a minimum distance at all times in dependenceof the usage profile of the system.

There are a number of sensors that attempt to monitor the thermal energycontent within a vessel.

One such example comprises a mechanical water level sensing arrangementoperating alongside a means of measuring the electricity consumption ofa heating element. However, a mechanical approach is compromised bymoving parts, fouling and cost.

An alternative comprises a single thermistor detector. Singletemperature measurement may provide an indication of a full tank.However, ignorance of a temperature distribution throughout a vesselprevents a user from determining the remaining quantity of useful heator cooling potential.

A further alternative comprises a plurality of temperature sensors. Aplurality of temperature sensors results in a compromise between theaccuracy of measurement (governed by number density of temperaturesensors) and the cost and complexity associated with monitoring multiplechannels simultaneously.

Further still, an alternative sensor comprises a resistive strip made upof a string of thermistors. A string of Positive Temperature Coefficient(PTC) or Negative Temperature Coefficient (NTC) thermistors can resolvethe average temperature within a vessel. However, knowing only theaverage temperature within the vessel is insufficient in determining theuseful volume above a particular threshold temperature. Furthermore, theresponse of a PTC string is non-linear resulting in large error comparedwith an ideal response. A string of NTCs is not well suited to resolvethe lower limit of the integral in Equation 1 and 2, resulting in a lackof knowledge of the threshold temperature above which useful energy(also referred to as exergy) content exists.

According to the present invention, there is provided a sensor formeasuring temperature of a fluid within a vessel, the vessel having afirst region (such as adjacent a fluid inlet) and a second region (suchas adjacent a fluid outlet) and the fluid having a temperature profileextending between the first region and the second region, the sensorcomprising an array of elements, each element having atemperature-dependent parameter, the array being capable of deploymentin association with (typically within or adjacent) the vessel such thatthe array extends along the vessel for measuring the temperatureprofile, the elements of the array being coupled together between aninput and an output, the input being coupled (or capable of beingcoupled) to a driving source for driving the sensor(s), and the outputbeing coupled (or capable of being coupled) to a detector for measuringan aggregate of the temperature-dependent parameter from the array ofelements.

Further features of the invention are characterised by the dependentclaims.

Preferably, the elements of the array are coupled in a chain.

Preferably, an aggregate value of the temperature-dependent parameter isindicative of thermal energy content of the fluid in the vessel.

Preferably, the aggregate value of the temperature-dependent parameterhas a predetermined relationship to the thermal energy content of thefluid in the vessel.

Preferably, at least one of the elements of the array is configured suchthat the temperature-dependence of the temperature-dependent parameteris at or near a maximum or minimum at or near a temperature that is athreshold temperature between a useful temperature of the fluid and anon-useful temperature of the fluid.

The temperature-dependent parameter may be resistance, impedance,inductance and/or capacitance.

The elements of the array may be coupled together in series or parallel.

The elements of the array may comprise at least one thermistor.

At least one of the elements of the array may comprise a PositiveTemperature Coefficient resistor and/or a Negative TemperatureCoefficient resistor and/or a fixed value resistor.

At least one of the elements of the array may comprise a fixed valueresistor connected in parallel with a Positive Temperature Coefficientresistor and/or a fixed value resistor connected in parallel with aNegative Temperature Coefficient resistor.

At least one of the elements of the array may comprise a PositiveTemperature Coefficient resistor connected in parallel with a NegativeTemperature Coefficient resistor and in series thereto a fixed valueresistor.

Preferably, the Positive Temperature Coefficient resistor and/orNegative Temperature Coefficient resistor is a non-linear resistor.

The elements of the array may comprise at least one electronic filtercircuit, including, but not exclusive to, RC, RL and RLC circuits.Preferably, each element of the array has a predetermined and uniquecut-off frequency, preferably at a pre-determined temperature.

Preferably, the sensor is arranged such that selective interrogation ofelements of the array can be achieved by exploiting (or using), theunique cut-off frequency of the elements of the array, preferably todetermine an interrogated cut-off frequency. Preferably the sensor isarranged to be selectively interrogated by the driving source byapplying a frequency sweep around the unique cut-off frequency.

Preferably, the sensor is arranged such that selective interrogation ofelements of the array comprises finding an interrogated cut-offfrequency or measurement of a temperature dependent parameter.

Preferably, the selective interrogation of elements of the arraycomprises finding an interrogated cut-off frequency wherein thetemperature-dependent parameter is the interrogated cut-off frequencyand wherein the relationship between the predetermined cut-off frequencyand interrogated cut-off frequency is used to determine a measure oftemperature.

Preferably, the relationship between predetermined and interrogatedcut-off frequency is indicative of a temperature.

Preferably, the temperature dependent resistance of a thermistor isindicative of a temperature.

The elements of the array may comprise at least one RLC circuit.Preferably, each element of the array has a predetermined and uniqueresonant frequency, preferably at a predetermined, temperature and thesensor is arranged to find the resonant frequency.

Preferably, the sensor is arranged to be selectively interrogated inorder to find an interrogated resonant frequency of interrogate elementsof the array to find the resonant frequency. Preferably the relationshipbetween predetermined and interrogated resonant frequency is indicativeof a temperature.

Preferably, the relationship between predetermined and interrogatedresonant frequency is indicative of a temperature.

Preferably, the relationship between predetermined and interrogatedresonant frequency, indicative of temperature, further indicates thethermal energy content of the fluid in the vessel.

Preferably, the detector is arranged to derive the thermal energycontent of the fluid in the vessel from the relationship between thepredetermined and interrogated resonant frequencies.

The elements of the array may comprise at least one semiconductingdevice.

Preferably, the semiconducting device element of the array is biasableto enable manipulation of the threshold temperature.

Preferably, the array comprises a substrate that can be cut to length todetermine the number of elements within the array. A substrate canprovide support and enable manipulation of the array so as to enablecutting.

Preferably, the substrate comprises a pipe. A pipe can provide a simpleand economical substrate that shelters and protects the array andprovides support.

Preferably, the substrate comprises an adhesive tape. This can enablefixation of the array to a vessel wall. Alternatively, the substrate maycomprise a flexible strip or flexible circuit board.

Preferably, the sensor is arranged within a vessel or externally to thevessel.

The elements of the array may be non-uniformly distributed along thelength of the sensor array according to sensing requirements.

According to a further aspect of the invention, there is provided asensing arrangement comprising a sensor (optionally according to theabove description), and at least one thermometer, the sensor and said atleast one thermometer having a shared output.

Preferably, the sensor and said at least one thermometer are coupledtogether such that there are only two output connectors for the sharedoutput.

Preferably, the sensor and said at least one thermometer are arranged inparallel.

Preferably, the sensor comprises means for measuring an output from thethermometer separately to the output from the sensor.

Preferably, the thermometer monitors the temperature adjacent the vesseloutlet or inlet to detect when fluid is at an unsanitary temperature;

Preferably, the output of the at least one thermometer is used todetermine the useful volume of fluid within the vessel and/or calibratethe output of the sensor. Preferably, the at least one thermometer isused to measure the temperature of fluid at an inlet of the vessel inorder to determine or improve the estimate of the useful volume of fluidassociated with a predetermined threshold temperature. Preferably, thetemperature of fluid at an outlet, measured by the at least onethermometer, allows identification of unsanitary exposures and providesa calibration reference from the sensor; hence a record can be madewhere fluid is at an unsanitary temperature, for example a temperatureof less than 70° C., 60° C., or, more preferably, less than 50° C.

Preferably, the detector comprises a means of adjusting the output ofthe sensor in dependence of the output of the thermometer, preferablyaccording to Equation 1; hence the accuracy of the sensor is correlatedto the thermometer, thereby improving accuracy of the sensor output orvice versa.

Preferably the thermometer is arranged to normalise the output of thesensor, in order to improve accuracy of the sensor.

According to another aspect of the invention there is provided a fluidtemperature controller comprising a first input for receiving a firstsignal indicating a measurement of an aggregate of atemperature-dependent parameter from a sensor, preferably comprising anarray of elements that have a temperature-dependent parameter, deployedwithin or adjacent a vessel containing a fluid having a temperatureprofile, a second input for receiving a second signal, optionally from athermometer as described above, indicating a temperature, preferably anabsolute temperature, of the fluid in the vessel, preferably adjacentthe location of the thermometer, and a processor configured to calculatea total thermal energy of the fluid in the vessel based on the first andsecond signals.

The fluid temperature controller may be further configured to determinea volume of useful fluid in the vessel further based on a predeterminedthreshold temperature between a useful temperature of the fluid and anon-useful temperature of the fluid.

Preferably, the processor is further configured to provide an outputcontrol signal for controlling a thermal source that changes thetemperature of the fluid in the vessel. The fluid temperature controllermay be further configured to determine an appropriate timing for theoutput control signal based on timing patterns of at least the firstsignal. Preferably, the fluid temperature controller is arranged toprovide the output control signal to the thermal source based onhistorical variations of at least the first signal.

Preferably, the processor is further configured to account for anynumber of array elements and/or array element spacing along the lengthof the sensor. Preferably, the processor is configured to operate independence upon the number of array elements and/or array elementspacing along the length of the sensor.

The fluid temperature controller may comprise a network stress monitor,the network stress monitor being arranged preferably to receive datafrom a network operator and to modify the output control signal to aheating element or the thermal source, preferably in dependence of thedata received from the network operator, to optimise the timing ofdispatch of thermal energy. This can enable a heating element controllerto regulate power consumption so as to take advantage of supply peaks inthe supply network, and avoid supply troughs in the supply network. Thiscan provide a supply balancing effect to the supplier and a cost benefitto the user.

Preferably, the network stress monitor modifies the output controlsignal to the heating element or thermal source in dependence on thesupply network voltage and/or grid current frequency.

Preferably, the network stress monitor modifies the output controlsignal to the heating element or thermal source in dependence on datafrom a network operator. A sensor as described above may provide thefirst signal.

According to a further aspect of the invention, there is provided acombination comprising a sensing arrangement (optionally as describedabove) and a controller arranged to process the shared output from thesensing arrangement, wherein the sensing arrangement and/or controlleris arranged to determine signals from the sensor and at least onethermometer separately and to compute the useful quantity of thermalenergy within a vessel containing a fluid.

Preferably, the combination is arranged to determine signals from thesensor and thermometer separately by impedance isolation of thethermometer.

Preferably, the combination is arranged to determine signals from thesensor and thermometer separately by using alternating current anddirect current

Preferably, the combination comprises multiple thermometers, preferablyin conjunction with network of thermistors.

Preferably the sensing arrangement is arranged to indicate if the amountof fluid within the vessel above the unsanitary temperature, asdescribed above, falls below a predetermined threshold.

According to yet a further aspect of the invention, there is provided adevice for identifying removal of fluid from a vessel, comprising: means(such as an input) for receiving an output from a sensor, the outputrelating to a thermal property of the fluid within the vessel, and aprocessor arranged to identify removal of the fluid from the vessel independence on a rate of change of the output from the sensor and apredetermined threshold value of the output. By identifying removal offluid from the vessel, usage of fluid of fluid can be logged.

Preferably, the threshold is arranged to be equal to or greater thanstatic heat loss from the vessel; preventing changes in output from thesensor from being interpreted as removal of fluid from the vessel.

Preferably, the device comprises an output for outputting an instructionto induce a temperature change in the fluid within the vessel when thedevice identifies removal of fluid from the vessel.

Preferably, the processor has an input arranged to indicate when atemperature change is being induced in the fluid, the processor beingarranged to modify the rate of change of the output from the sensor soas to cancel/mitigate the effects of the induced temperature change inthe fluid to identify removal of fluid from the vessel. Preferably, thedevice is arranged to isolate effects to the rate of change of theoutput from the sensor due to activity from the thermal source,preferably by receiving information regarding scheduled times ofactivity of the thermal source. Preferably, the device is arranged tofactor-in any contribution from a heat source or thermal source so thatthe change in a useful volume of fluid due to removal of fluid from thevessel can be decoupled from the total change in sensor output whilst asimultaneous heating event occurs. Preferably, the device is arranged tomonitor changes in the output of the sensor for the purpose ofdis-aggregating draw and heating events, or measures identified asremoval of fluid from the vessel, from the continuous change due tostanding heat losses. Preferably, with knowledge of the heat sourcetiming and controller of the heat source is also able to decouple a drawevent when simultaneous heating occurs. Preferably, the useful volume offluid due to removal of fluid can be isolated or decoupled from thetotal change in output from the sensor, preferably while the thermalsource is active.

According to another aspect of the invention, there is provided a systemcomprising a device (optionally as described above), said sensor andsaid vessel, the sensor being located adjacent an outlet of the vessel.

According to another aspect of the invention, there is provided a devicefor measuring temperature of a fluid within a vessel, the devicecomprising: a sensor (optionally as described above) for determining athermal property of a fluid within a vessel, wherein the sensor isarranged to be fitted onto an exterior wall of the vessel; and aprocessor for receiving the output from the sensor and adjusting theoutput according to thermal properties of the wall of the vessel.Thereby, the accuracy of the output from a sensor arranged to inferthermal properties of a fluid through a vessel wall may be improved.

Preferably, said sensor comprises an array of elements, each elementbeing adapted to determine a thermal property at a different location onthe vessel.

Preferably, wherein the processor uses a model of the wall of thevessel.

According to another aspect of the invention there is provided a devicefor measuring temperature of a fluid within a vessel, the devicecomprising: a sensor (optionally as described above), for determining auseful volume of a fluid within a vessel, wherein the sensor is arrangedto be fitted onto an exterior wall of the vessel; and a processor forreceiving an output from the sensor and adjusting the output from thesensor in dependence upon changes induced in the fluid by a thermalsource or the influence of the thermal source on a useful volume offluid within the vessel.

The invention extends to a system comprising a vessel, the vessel havinga first region (such as adjacent a fluid inlet) and a second region(such as adjacent a fluid outlet) and the fluid having a temperatureprofile extending between the first region and the second region, asensor or a sensing arrangement (optionally as described above) and afluid temperature controller (optionally as described above).

The fluid in the system may be gas or liquid.

The system may comprise a vessel that is a hot water tank, a fluid thatis water and a threshold temperature comprising a temperature beneathwhich the water is too cold or not useful, for example, below atemperature of 60° C., 50° C., 40° C. or 30° C., for direct use as hotwater.

The system may comprise a vessel that is a coolant tank, a fluid that isa coolant and a threshold temperature comprising a temperature beneathwhich the fluid is too hot for direct use as a coolant.

The invention extends to a sensor, controller, device and system,substantially as herein described with reference to the accompanyingfigures.

According to another aspect of the invention there is provided acontroller arranged to interpret the signal from a thermocline sensor(optionally as described above) and, on the basis of that signal,compute the useful quantity of thermal energy within a vessel containinga liquid.

Preferably, the controller is capable of modulating the timing andquantities of any thermal inputs or outputs from a vessel containing aliquid on the basis of a user requirement and thermocline positionmeasurement derived from a thermocline sensor as described in thisdocument.

Preferably, the controller can track cyclical patterns of signal outputfrom a thermocline sensor within a vessel containing a liquid, orpreferably externally to the vessel, and on this basis optimise thedispatch of thermal energy using any other additional parameters such asuser input, user requirement, energy cost, distribution network voltageand/or grid frequency and in the case of domestic hot water systems,sanitary requirements.

Preferably, the controller can provide a user with an indication of theuseful volume of thermal energy on the basis of the signal produced by athermocline sensor.

Preferably, the thermocline sensor's output signal is combined with oneor more temperature signals to provide a reference to a controllerwithin which the useful quantity of energy is computed.

Preferably, the thermocline sensor is physically immersed within avessel containing a fluid or is in physical contact with the wall of avessel, preferably on an interior or exterior wall of the vessel,containing a liquid so that the temperature distribution and associateduseful quantity of thermal energy within the liquid can be inferred.

Preferably, the thermocline sensor comprises a number of temperaturemeasuring elements whose outputs are aggregated in such a way as toprovide one or more signals that describe the useful quantity of thermalenergy within a vessel.

Preferably, the thermocline sensor comprises of a number of resistiveelements exhibiting a fixed value or negative or positive relationshipwith temperature.

Preferably, the thermocline sensor's total network resistance is afunction of the quantity of energy and temperature distribution within aliquid stored in a vessel.

Preferably, the thermocline sensor's resistive elements are connected ina series or parallel arrangement.

Preferably, the thermocline sensor comprises of an arrangement ofindividual Thermocline Edge Detectors (TEDs) further comprising ofpositive or negative coefficient thermistors in parallel with anotherresistive element such as a fixed value resistor.

Preferably, the thermocline sensor comprises any number of TEDs arrangedin a series or parallel configuration.

Preferably, the TEDs are designed to abruptly change in resistanceaccording to the passing of a thermocline within a body of stratifiedliquid within a vessel.

Preferably, the TEDs response is achieved through the selection of theCurie transition temperature associated with a positive temperaturecoefficient thermistor.

Preferably, the accuracy of the TEDs and resistance-to-useful volumerelationship is optimised via addition of parallel or series negativetemperature coefficient or positive temperature coefficient thermistors,resistors or any other resistive element.

Preferably, the thermocline sensor's network resistance values aredetermined by any means, such as voltage measurement associated with aknown current; current measurement associated with a known voltage,timing of current change in or voltage change across an inductor orcapacitor connected to or within resistive network.

Preferably, the thermocline sensor comprises of a number of reactiveelements exhibiting some dependence on temperature.

Preferably, the thermocline sensor or TEDs comprises a temperaturereference sensor for inferring useful volume delivered to an end user.

Preferably, the thermocline sensor or TEDs comprise a temperaturereference sensor for monitoring a hot outlet of the vessel to recordpotentially unsanitary exposures to hot water, for example less than 60°C., 50° C., 40° C. or 30° C. Preferably, an inlet temperature referencefrom the temperature reference can be used to improve the estimate ofuseable volume through application of Equation 1.

Preferably, the controller is capable of measuring the impedance of athermocline sensor in order to compute the useful volume of thermalenergy within a vessel filled with a liquid using any impedancemeasurement technique, such as, but not limited to, frequency magnitudeand/or phase response and/or impulse response test from some arbitraryinput waveform to reactive network.

Preferably the controller is arranged to apply a wall heat fluxfunction, preferably applied to a resistive thermal model to correctmeasures of temperature of the vessel wall in order to determine thetemperature of the fluid within the vessel.

Preferably, the controller comprises means, such as a processor, ofmapping a wall heat flux function for the temperature and temperaturegradient of the external vessel wall to an empirical or computedrelationship between a wall position and heat flux, wherein a simplifiedfunction is parameterised on the basis of features, for example thermalparameters, of the vessel wall, temperature measures of the vessel walland the temperature gradient.

Preferably, the wall heat flux function further comprises a model foradjusting for the effects of thermal transient effects associated withfluid flow, heat capacitance and conduction to the ambient environmentof the vessel and fluid.

Preferably, the controller comprises a processor for mapping atemperature profile of the vessel wall and/or fluid within the vessel,to an output from a thermal source for a given flow rate and temperatureof an inlet of the vessel. Preferably, the processor is arranged toapply a model of the thermal source to a one-dimensional ortwo-dimensional model of the fluid within the vessel, preferably formodelling the stratification of the fluid, in order to resolve ordetermine a change in the rate of change of temperature of fluidadjacent to the outlet of the vessel, for a given flow rate of fluidinto or out of the vessel for a given temperature adjacent the inlet ofthe vessel. Preferably, the processor is arranged to determine theuseful volume of energy or mass of hot water above a predetermineduseful temperature.

Preferably, the controller comprises a device for identify removal offluid from the vessel in dependence of the rate of change in output fromthe thermocline sensor or a temperature sensor array. Preferably, thecontroller is arranged to output an instruction to activate a thermalsource in dependence of identification of removal of fluid from thevessel. Preferably, the processor is arranged to use machine learning toinstruct the thermal source. Preferably, the processor is arranged todetermine if the volume of useful fluid within the vessel is below apredetermined threshold. Preferably, the processor is arranged toindicate to a user if volume of useful fluid within the vessel is belowa predetermined threshold.

The invention extends to methods and/or apparatus substantially asherein described with reference to the accompanying drawings.

Any apparatus feature as described herein may also be provided as amethod feature, and vice versa. As used herein, means plus functionfeatures may be expressed alternatively in terms of their correspondingstructure, such as a suitably programmed processor and associatedmemory.

Any feature in one aspect of the invention may be applied to otheraspects of the invention, in any appropriate combination. In particular,method aspects may be applied to apparatus aspects, and vice versa.Furthermore, any, some and/or all features in one aspect can be appliedto any, some and/or all features in any other aspect, in any appropriatecombination.

It should also be appreciated that particular combinations of thevarious features described and defined in any aspects of the inventioncan be implemented and/or supplied and/or used independently.

These and other aspects of the present invention will become apparentfrom the following exemplary embodiments that are described withreference to the following figures in which:

FIG. 1 shows a fluid storage vessel annotated to show the schematiccommunication between a sensor, fluid temperature controller, heatingelement and fluid outlet;

FIG. 2 a) shows a sensor-fluid outlet pipe interface for horizontaloutlet connections;

FIG. 2 b) shows a sensor-fluid outlet pipe interface for vertical outletconnections;

FIG. 3 a) shows a sensor comprising of Thermocline Edge Detectors (TEDs)in series;

FIG. 3 b) shows a sensor comprising of Thermocline Edge Detectors (TEDs)in parallel;

FIG. 4 a) is a circuit diagram of a sensor with TEDs in series;

FIG. 4 b) is a circuit diagram of a sensor with TEDs in parallel;

FIG. 5 shows the temperature dependence of the resistance of a TED;

FIG. 6 is a circuit diagram of a further exemplary TED;

FIG. 7 is a circuit diagram of a sensor with RC-based TEDs;

FIG. 8 is a circuit diagram of a sensor with diode-based TEDs;

FIG. 9 is a circuit diagram of a sensor with grounded gate/basetransistor-based TEDs;

FIG. 10 is a circuit diagram of a sensor with biased gate/basetransistor-based TEDs;

FIG. 11 is a schematic diagram of a thermocline sensor with an impedanceisolated temperature sensor relative to a vessel;

FIG. 12 is a further diagram of a thermocline sensor with multipleimpedance isolated temperature sensors;

FIG. 13 shows AC and DC operation of the thermocline sensor andimpedance isolated temperature sensors;

FIG. 14 is a process flow diagram showing processing of the signal fromthe thermocline sensor;

FIG. 15 shows a device for identifying draw events; and

FIG. 16 shows a device for correcting for thermal effects of a vesselwall.

FIG. 1 shows a fluid temperature controller 100 comprising a first inputfor receiving a first signal 102 indicating a measurement of anaggregate of a temperature-dependent parameter from a sensor 104 withinor adjacent a vessel 106 (for example, on an interior or exterior wallof the vessel) containing a fluid, either liquid or gas, having atemperature profile. The fluid temperature controller 100 has a secondinput for receiving a second signal 108 indicating a temperature of thefluid in the vessel. A processor 110 in communication with thecontroller is configured to calculate thermal energy of the fluid in thevessel based on the first and second signals. A linear exergy sensor istherefore provided.

The processor 110 is further configured to determine a volume of usefulfluid in the vessel based on the first signal 102 and second signal 108and a predetermined threshold temperature between a useful temperatureof the fluid and a non-useful temperature of the fluid. The processor ofthe controller computes the useful volume of fluid available in thevessel 106. The computation by the processor can be according to anequation similar in form to Equation 1 or 2. If the sensor 104 performsaccording the Equation 1 or 2, then the processor can apply signalconditioning to compute the useful volume of fluid available in thevessel 106. The sensor 104 is therefore a linear exergy sensor and thelinear exergy sensor provides a signal that provides weight to theuseful energy above the threshold temperature (rather than a binaryindication beyond a useful temperature).

The processor 110 is configured to provide an output control signal tothe controller 100, which in turn produces an output 114 that regulatesa thermal source 116 (e.g. a heating element in the case of an electricsystem) so as to change the temperature of the fluid in the vessel. Thecontroller determines whether the proximity of the thermocline to thevessel outlet 118 is such that there is an insufficient useful amount ofvolume of fluid and thus a risk of a user 120 being exposed to fluidwhich is at an insufficient temperature. Furthermore, the controlleraims to prevent a user from being exposed to pathogenic bacteria thatcould dwell beneath the lowest thermal injection point (in theillustrated example the thermal source 116), whilst at the same timeminimising standing heat losses. If such sanitary risks arise on aregular basis, the controller 100 can arrange for additional thermalenergy to be added as a preventative measure in advance.

The fluid proceeds along the fluid outlet 118 whereupon it is mixed withfluid from a cold inlet 122, the output of which is regulated by amixing valve 124, and the fluid emerges in a mixed outlet 126. The fluidin the vessel 106 is replenished through a cold inlet 121. A temperatureprofile extends between the cold (inlet) region in the vessel 106 andthe hot (outlet) region in the vessel 118. The temperature profile mayexhibit a distinct thermocline, or it may exhibit a gradual transition.

The output control signal that the processor 110 provides to thecontroller 100 is subject to approval from or adaptation by a networkstress monitor 112. The network stress monitor 112 can modify the outputcontrol signal in dependence on factors that relate to the networkstress. For example, the supply voltage, supply frequency data, or datacommunications from the supply provider 134 can provide informationrelating to the network stress. Optionally or alternatively thecontroller 100 can interact with the supply provider 134 to affectdispatch of energy based on network stress information, and so enabledispatch of energy to the vessel according to availability of energy inthe vessel and the cost of energy.

The processor 110 can relate cyclic changes in output from the sensor104, for example over a 24-hour period, to determine, in addition toother parameters such as energy costs, user input 128, user 120requirements, the optimal timing associated with any thermal inputs oroutputs from a vessel 106 containing a fluid, distribution in networkvoltage and/or grid frequency as determined by the network stressmonitor 112. An adaptive Markov model, or similar statistical approach,could run on the controller and adjust probability weightings assignedto future draw events based on previous draw events and theirassociations with particular activities (for example the probability ofa shower within an hour after a user has drawn a bath) along with thetime of day. The Markov model predicts the most likely future demand toallow an algorithm to establish the optimal dispatch of power toimmersion elements. A machine-learning process is used to optimallyschedule heating of fluid within the vessel according to use of thefluid in the vessel.

The fluid temperature controller 100 is able to output information 130regarding the quantity of fluid above (in the case of hot fluidapplications) a useful temperature in addition to its mixing potentialto the user 120.

The signal from the sensor 104 is supplemented by an additionaltemperature sensing input to yield absolute temperature readings 108 inorder to normalise the response of the sensor during cyclical operation.

In one embodiment, the sensor 104 is immersed within the fluid insidethe vessel 106. The sensor 104 can be in contact with the vessel wall200, hence providing an indication of the temperature distribution. Inthis case, the sensor 104 can be fixed to the inner or outer surface ofthe vessel wall 200.

FIG. 2a illustrates a mechanical arrangement whereby a protrusion from asensor-pipe interface 202 from a section of pipe 204 clears (via anoptional step) the flange recess shoulder 206. For vessels withhorizontal outlet connections, the protrusion 202 bends through 90°before continuing down towards the bottom or up towards the top of thevessel. The circuitry associated with the sensor is embedded in thesensor strip 104. The wiring associated with the sensor is embedded inthe sensor strip, protrusion 202 and pipe 204 wall prior to emerging asthe connecting wire 208 carrying the sensor output 102. The wire 208terminates at a suitable connector, for example, a two or more pinnedconnector. The sensor-pipe interface 202 connects to the tank flange 210and fluid distribution system via compression, push-fit, bolted flangeor any other appropriate arrangement 212. FIG. 2b illustrates amechanical arrangement for vessels with vertical connections. The sensor104 protrudes vertically from the sensor-pipe interface 202 into thevessel, with no bend. FIGS. 2a and 2b show ¾ inch British Standard Pipe(BSP) external threaded compression fittings, which are exemplaryfittings that are commonly found in UK domestic hot water systems.

FIGS. 3a and 3b show sensors 104 with Thermocline Edge Detectors (TEDs)300. Each TED 300 is an element in an array of similar elements. In FIG.3a TEDs 300 are connected in series. In FIG. 3b TEDs 300 are connectedin parallel, where the individual TEDs 300 can act as shunts. The TEDs300 are such that the sensor's temperature response follows Equation 1or 2 (whether or not a temperature profile exhibits a thermocline). TheTEDs 300 have a temperature-dependent parameter that gives rise to atemperature response, e.g. changes in resistance or AC impedance. Theresistance, impedance or rise time for a temperature-dependent RCnetwork is inferred by: applying a fixed voltage across the sensorterminals; applying a known frequency across the sensor electricterminals 302; injecting a known current through the sensor; ormonitoring the response to an impulse or any other arbitrary inputfunction of current or voltage over time. A measure of impedance is madeat terminals 302; this is achieved by wiring the network to a fixedresistor with known reference voltage and recording the voltage acrossthe terminals 302 as in a voltage divider circuit, or throughmeasurement of a voltage drop on application of a known constantcurrent.

Any number of TEDs 300 can be arranged in a series or parallel chain toprovide indication of the total thermal energy in the vessel. Thepositioning and spacing of the TEDs 300 within the sensor strip 104 canvary according to sensing requirements. For example, a higher resolutionis required close to the vessel outlet 118 to determine thermoclineposition with greater accuracy and thus potential sanitary risk to asystem user.

Whilst independent wiring of TEDs 300, PTC thermistor or NTC thermistorarrays provides the most accurate resolution of useful volume, thisapproach also requires multiple electrical connections and channelswithin the signal conditioning arrangement. The sensors 104 describedhere require a single measurement channel reducing cost and complexitywhilst improving reliability. The linear exergy sensor therefore feedsone signal to the control unit from the network of thermosensitiveelements. In addition, for the output of sensors wherein resistance isexploited as the temperature-dependent parameter used to indicate usefulvolumes of fluid, only gain and bias requirements are imposed on signalconditioning, whereas some form of numerical integration of the outputof an independent array is required for the same purpose increasing thecomplexity of any algorithm making the measurement.

FIG. 4a shows a circuit diagram of a sensor 104 comprised of an array ofTEDs 300 connected in series. FIG. 4b shows a sensor 104 with an arrayof the same TEDs 300 as FIG. 4 a, but with the TEDs 300 connected inparallel. Each illustrated TED 300 comprises three elements: athermistor 400 in parallel to a resistive element 402 and in seriesthereto a resistor 404. The elements within a TED 300 can act as shunts.The thermistor 400 can be a PTC or NTC thermistor. The resistive element402 is shown as a resistor, but it can alternatively be a PTC or NTCthermistor or another resistive element. The resistor 404 can beomitted.

The resistance of networks such as in FIGS. 4a and 4b is inferred viacurrent measurement with constant voltage or voltage measurement withconstant current. The current drawn by the sensor for a fixed voltagecorresponds to an aggregate of temperature-dependent resistance of theTEDs, which corresponds with the useful volume once the appropriatesignal conditioning has been applied. The aggregatedtemperature-dependent resistance is a cumulative summation of theresistance of the elements (or a selection of the elements) of thesensor array.

FIG. 5 shows the temperature dependence of the resistance of a TED. Theideal resistance curve 500 (dashed line) represents an ideal TED withconstant resistance up until the Curie temperature 502 of thethermistor; above the Curie temperature 502, the resistance increaseslinearly with temperature. A typical resistance curve 504 (black solidline) of a real-world thermistor is not linear, nor is there a distincttransfer from a constant-resistance regime to a linear-increasingregime. A TED circuit designed to approximate the ideal resistance curve500 has a PTC thermistor in parallel with a fixed value resistor. TheTED circuit curve 506 (grey solid line) of this circuit behavessignificantly more closely to the ideal curve 500 than does thethermistor on its own (typical thermistor curve 504). For a TED with anNTC thermistor an ideal resistance curve 508 (dashed line) is alsoshown, and the typical real-world thermistor resistance curve and TEDcircuit curve are analogous to the illustrated PTC curves. Forapplications where an upper threshold temperature is relevant (inaddition to the lower threshold of the Curie temperature 502 asdescribed above), a curve with an upper temperature threshold, afterwhich the resistance remains constant again, can be implemented,analogous to the illustrated curves.

The sensor 104 in FIG. 4 a, comprising a chain of TEDs 300 connected inseries, applied to determining the useful volume of hot fluid within avessel, solves Equation 1 numerically by scaling and biasing the changein terminal resistance of the thermocline sensor according to Equation3,

$\begin{matrix}{{\int_{y{(T_{thresh})}}^{h}{{{A(y)}\left\lbrack {1 + \frac{{T(y)} - T_{thresh}}{T_{thresh} - T_{c}}} \right\rbrack}dy}} \approx {{K\left\lbrack {\sum\limits_{n = {{TED}@T_{thresh}}}^{N}{R_{TED}(T)}} \right\rbrack} - {N\; {\beta.}}}} & (3)\end{matrix}$

For a given TED, index n, the temperature-dependent resistance,represented by R_(TED)(T), is only effective above the component's Curietemperature. Therefore, the cumulative resistance on the right-hand sideof Equation 3 only includes temperature-dependence associated with TEDsimmersed at a temperature above the Curie transition temperature. TheCurie transition temperature is selected to coincide with thethermocline transition temperature of interest and thus sets T_(thresh).For T(y)<T_(thresh), R_(TED)(T)≠0, so the bias term, Nβ, is required,where N is the total number of TEDs and β is the asymptote resistancefor R_(TED)(T<T_(thresh)). The gain term, K, scales R_(TED)(T) back toT(y) and in addition includes the term A/T_(thresh). For the parallelarrangement of TEDs 300 shown in FIG. 4 b, the useful volume of hotfluid within a vessel is solved by Equation 3 manipulated to account forthe manner in which a parallel configuration of TEDs accumulatesresistance. The thermistor elements provide an integral limit above aspecified threshold temperature.

For determining a useful volume of coolant within a vessel, the sensors104 illustrated in FIGS. 4a and 4b are comprised of TEDs where thethermistors 400 alternate along the sensor between PTC and NTCfunctionality. This arrangement numerically solves Equation 2 and cantherefore be used to determine a useful volume of coolant below athreshold temperature. The sensor accuracy can be further improved byusing an NTC thermistor parallel to a PTC thermistor instead of a fixedresistor parallel to a PTC or NTC thermistor.

An ideal TED responds to temperature transition across a threshold withan instantaneous transition from the temperature-independent regime tothe temperature-dependent regime at a temperature associated with thethermocline transition temperature. In practice a TED may not display anabrupt change from the temperature-independent regime to thetemperature-dependent regime, but instead displays a departure from theideal function resulting in a function departure error. The presence ofthe parallel resistor 402 ensures that there is a linear response totemperature beyond the thermistor's Curie transition point. This helpscreate a more abrupt transition in resistance and manifests itself as alower function departure error from the ideal function when thetemperature of a particular section of the network crosses the thresholdtemperature. Without a parallel resistive element 402 the functiondeparture error becomes very large and traverses a wide range oftemperatures when compared with the response for a sensor inclusive of aresistive element 402 parallel to a PTC or NTC. Preferably a resistiveelement is connected in parallel to each TED to minimise the functiondeparture error.

A benefit of a sensor comprising TEDs coupled in parallel is that anynumber of TEDs can be integrated into a strip which can be cut to theappropriate length or number of TEDs without loss of function to enableeasy retrofit for a given installation. The controller 100 can becalibrated to a variety of sensor cut lengths either by having thecorresponding response pre-programmed for a given length, or bynormalising the sensor output to a known reference state such as a fullyheated or fully cold vessel of fluid.

The controller is capable of conditioning the resistance measurementsuch that a variable describing the quantity of useful energy remainingin a vessel is available. A parameter indicative of total thermal exergywithin the vessel is therefore obtained.

FIG. 6 illustrates a sensor comprising a further example of a resistivetemperature reactive network 300 that solves Equation 1 or 2 for thepurposes of determining the useful heating or cooling fluid volumewithin a vessel in a discretised manner with no more than two electricalterminals 302.

FIG. 7 shows an alternative arrangement for a sensor 104 with a parallelarrangement of TEDs 300, each TED comprising a capacitor 700 in serieswith a temperature-dependent resistive element 400, thus forming an RChigh-pass filter circuit. A sensor comprised of a serial configurationof RC-based TEDs is equally suitable. Throughout the TEDs in the sensorarray, capacitors are selected to possess unique value capacitances,with the positions of particular unique value capacitances defined.Along the array identical NTC resistors are used. Therefore each TEDpossesses a unique predetermined cut-off frequency associated with theRC filter.

Selective interrogation of capacitive TEDs is achieved by driving thesensor with a sine wave signal at a low enough frequency such that thehighest value capacitor (also associated with the RC circuit with thelowest cut-off frequency) behaves as a short circuit. The accompanyingserial NTC thermistor's resistance governs the current drawn into thesensor array, which is proportional to the temperature of thethermistor. The signal from the remaining TEDs is not accounted sincethe input frequency is selected such that the remaining capacitorspossess too little capacitance to admit current at this frequency and soappear as open circuits. The frequency is increased such that the secondhighest value capacitor behaves as a short circuit as the time constantassociated with the RC circuit the capacitor comprises is encountered.Any change in current is associated with the temperature of the NTCresistor in series with the second highest value capacitor. The processis performed such that the remaining temperatures of the NTC thermistorsin each TED are resolved in sequence allowing the temperature profile tobe determined. The unique value capacitances can be arranged in anarbitrary sequence, provided the position of the individual capacitancesis known. The process therefore utilises a frequency sweep in orderselectively to interrogate elements of the array.

The same effect as described above for capacitive TEDs can be achievedwith a sensor array comprising TEDs that more generally compriseelectronic filters (each having a unique value) which are selectivelyinterrogated within the array. Examples of suitable electronic filtersinclude RL filters, low-pass filters, bandpass filters and any othersimilar arrangements.

Instead of measuring resistance at a particular frequency to determine atemperature-dependent parameter, as described above, The temperature ata given TED can also be gauged by determining the shift betweenpredetermined cut-off frequency (that is, the cut-off frequency at acalibration temperature) and interrogated cut-off frequency (that is,the cut-off frequency at an actual, unknown, temperature to bemeasured). This allows the significant temperature-dependent parameterexhibited by some capacitors to be exploitable by having TEDs comprisingfixed resistors in series with temperature-dependent capacitors. EachTED comprises an RC circuit with a unique predetermined cut-offfrequency. The temperature at a given TED is inferred by selectivelyinterrogating TEDs by manipulating input frequency and determiningcapacitance or the shift between interrogated and predetermined cut-offfrequency. A temperature profile is thereby derived by accumulating theinferred temperature across the array.

Alternatively, an inductor can be introduced into the TEDs 300 shown inFIG. 7, thus forming an RLC circuit, which exhibits resonance. The RLCcircuit of each TED 300 possesses a unique predetermined resonantfrequency (via appropriate selection of fixed value resistors and/orNTC/PTC thermistors 400). The temperature associated with a particularRLC-based TED at a particular position is determined in isolation ofother TEDs by applying a frequency across the sensor terminals 302 whichis close to the predetermined resonant frequency associated with thatparticular TED. By modulating the applied frequency around thepredetermined resonant point for that particular TED, the true resonantfrequency can be found. The shift in resonant frequency exhibits atemperature-dependence from which temperature can be deduced. Byinterrogating the array in this manner, the temperature profilethroughout the vessel can be deduced directly. The computation ofEquation 1 or 2 is achieved via numerical integration of the resultingtemperature profile.

FIG. 8 shows a TED 300 configuration comprised of diodes 800 parallel toresistive elements 402 and the combination in series with furtherresistive elements 404. Multiple TEDs 300 are connected in parallel toform a sensor 104. The TEDs can act as shunts in the parallelarrangement. Diodes exhibit temperature-dependent phenomena with respectto forward operating, reverse breakdown and current leakage performancecharacteristics. The current drawn by the sensor for a fixed voltagecorresponds to an aggregate of temperature-dependent parameter of theTEDs, which corresponds with the useful volume once the appropriatesignal conditioning has been applied. The leakage or reverse breakdowncharacteristics and their dependence on temperature are exploited by theseries and parallel arrangements. Forward operating performance and itsdependence on temperature can be exploited by reversing the orientationof all diodes 800. A sensor comprised of a serial configuration ofdiode-based TEDs 300 is equally suitable.

FIG. 9 shows an arrangement of grounded gate/base transistor 900 TEDs300 connected in parallel to resistive elements 402; in turn thecombination is in series with further resistive elements 404. The TEDs300 are connected in parallel to form a sensor 104. The parallelarrangement of TEDs forms a shunt circuit. There is a variety oftransistor-based implementations that are conceivable including a numberof bipolar and field effect approaches.

Temperature-dependent phenomena associated with the intrinsic diode thatexists between the collector/emitter or drain/source are exploited alongwith any leakage characteristics as discussed for diodes. A sensorcomprised of a serial configuration of transistor-based TEDs 300 isequally suitable.

FIG. 10 shows an arrangement of biased gate/base transistor 1000 TEDs300 connected in parallel to resistive elements 402, which combinationis in series with further resistive elements 404. Reactive elements canbe used in place of the resistive elements 402. The TEDs 300 areconnected in parallel to form a sensor 104. The parallel arrangement ofTEDs forms a shunt circuit. In the biased transistor 1000 instance, nomore than three electrical terminals 302 are required to determine theuseful heating or coolant fluid volume. The biasing facilitates controlof the threshold temperature beyond which forward conduction takesplace. The arrangements in FIGS. 8, 9 and 10 can be based around anytype of semiconducting device such as field effect transistors, bipolartransistors, thyristors, etc. A sensor comprised of a serialconfiguration of biased-transistor-based TEDs 300 is equally suitable.

FIG. 11 shows a circuit 1100 with a thermocline sensor 104 comprising anarray of TEDs 300 (e.g. a shunt circuit with transistors or diodes—asdescribed with reference to FIGS. 1 to 10) in parallel to a thermometer1110 (as used herein, the term “thermometer” includes any form oftemperature sensor, and as such does not necessarily actually provide ameasurement of temperature). The thermometer 1110 is comprised of athermistor 1130 (NTC or PTC), having a resistance R_(r) in a serialarrangement with a capacitor 1120, with capacitance C. The arrangementof the circuit 1100 thereby allows a temperature reference from thethermometer 1110 to be determined separately to the output from thethermocline sensor 104, for example by using impedance isolation.Impedance isolation is, for example, afforded by the Resistor-Capacitor(RC) construction of the thermometer 1110 and by operating the circuit1100 so as to exploit the filter properties of the RC thermometer.Alternatively, impedance isolation is achievable using a thermometerwith an inductor, rather than capacitor (i.e. Resistor-Inductor). FIG.11 shows a combination comprising a circuit 1100 and a controller 100,wherein isolating signals from the thermocline sensor 104 andthermometer 1110 is achieved by the controller and/or arrangement of thecircuit 1100 and its components.

A signal indicative of the useable volume of water in the vessel 106 isobtained on application of a Direct Current (DC) signal—according to theresponse from the thermocline sensor 104—and a signal indicative oftemperature at the point of the thermometer 1110 on application of anAlternating Current (AC) signal. The thermometer 1110 also allows thesignal of the thermocline sensor 104 to be normalised.

In the example shown, a single thermometer 1110 is located at a pointaligned with the vessel outlet 118. TEDs 300 are placed within thevessel 106 or externally to the vessel. The thermometer 1110 provides ameasure of temperature adjacent its position.

It is advantageous for the circuit 1100, in particular the thermoclinesensor 104, to be fitted to an outside thermally conductive wall of thevessel 106, since this enables the circuit 1100 to be retrofit. However,for vessels 104 with highly conductive walls (such as thick, e.g. >1mm-3 mm, and/or British Standard grade 1 Copper walls) a significantdiscrepancy between the internal water and external wall temperaturesarises due to differences in heat transfer between the water within thevessel 104 and the vessel wall. The discrepancy—most significant whenthere is a thermocline with a steep temperature gradient across it—isobserved as a blurring of the otherwise sharp thermocline temperaturetransition point when inferring internal water temperature from thevessel wall. The accuracy to which the thermocline position isdetermined from measures of thermal properties of the vessel wall istherefore adversely affected. A model (referred to as a “wall model”herein) is used to obviate the thermal effects on measurements from asensor that measures the thermal properties of fluid within the vesselthrough the vessel wall. The temperature profile and/or thermal exergycontent of the fluid within the vessel, is available to be inferred by asensor, such as the thermocline sensor 104, on an external wall of aninsulated vessel, more accurately than without accounting for thethermal effects of the vessel wall. In one example, the wall modelallows a sensor to be located adjacent to a vessel wall when the vesseland sensor are assembled during original manufacturing (and not justretrofit); this allows the sensor to be fixed to the vessel and then theinsulation applied over the top of the vessel and sensor. The wall modelis adapted according to measurements from the thermometer 1150.

The wall model is based on the thermal dynamics of heat flux across thevessel wall due to a stratified body of water contained within thevessel and applying analytical and/or interpolative techniques (forexample a numerical spline method) in order to obtain a solution. In oneexample, a wall heat flux function that maps the temperature andtemperature gradient of the external wall of the vessel to an empiricalor computed relationship between a position on the vessel wall and heatflux is used, and parameterisation of such a function is used on thebasis of features of the vessel wall temperature and temperaturegradient.

More elaborate wall models, for example accounting for transient thermalconduction, are alternatively applied, wherein the influence of fluidflow within the vessel during operation, distributed heat capacitanceand conduction to the ambient environment is considered so that thesensor is capable of accounting for these effects.

Knowledge of the thermal dynamics of the vessel and fluid, allows theoutput of the thermocline sensor 104 to be fit to a thermal model of thevessel and fluid. The accuracy of measurements from the thermoclinesensor 104 is thereby maintained with fewer array elements, e.g. TEDs300. For example, 4-12 array elements allows for the thermal energy ofthe fluid to be suitably determined using; more preferably 7-9 arrayelements are used, but no fewer than 2-4 array elements are used.

In an alternative example, a linear exergy sensor composed ofindependent individual sensors traversing strata of fluid within avessel is used to obtain a temperature profile of the fluid. In oneexample, the independent array of sensors comprises at least one of: athermistor, thermocouple and/or any of the thermocline sensors 104described herein. A signal compressor is used to aggregate the outputsfrom the sensors in order to determine the position of the thermoclineand thus the thermal exergy of the fluid. When the number of independentsensors is small, e.g. <2-5 independent sensors, the output of theindependent sensors is fit to a thermal model in order to improve theaccuracy of the temperature profile, for example using regressions orinterpolation techniques (such as spline fitting).

FIG. 12 shows an alternative circuit 1200 to the example shown in FIG.11, whereby a plurality of thermometers 1110 are connected in parallelto the thermocline sensor 104 so as to traverse different positions ofthe vessel 106, for example the vessel outlet 118, inlet 121 and/orintermediate positions therein. In one example, the thermometers 1110are distributed along the vessel at isochoric intervals. The low passleg of the thermometer 1110 arrangement is replicated in the circuit1200 introducing additional pole and/or zero time terms for multipleimpedance isolated thermometers 1110 in different locations of thevessel 106. An array of impedance isolated thermometers 1110 allowsindividual temperature readings to be made for each thermometer 1110. Ameans of compiling a temperature profile of the fluid in the vessel isalso achieved by independently interrogating each thermometer 1110 ofsuch an array, and thereby aggregate a temperature profile of the fluidwithin the vessel.

The output of an array of thermometers 1150 is improved, when the arrayof thermometers is coupled with a sensor with finer resolution, such asa thermocline sensor 104 comprising a high number of PTC based TEDs 300.

The volume of useful fluid within the vessel is dependent upon both thetemperature distribution throughout the tank (detected either by thethermocline sensor 104 or an array of thermometers 1110) along with thetemperature of any cold water used for the purposes of mixing.Monitoring the temperature of the vessel inlet 121, for example using athermometer 1110, and making the assumption that this is representativeof inlet temperatures feeding appliances downstream of the vessel (e.g.the cold side of a shower mixer valve), Equation 1 is solved for theuseful volume of fluid. T_(c) as determined using, for example, athermometer 1110, is used to correct the gain and bias terms applied tothe output of the thermocline sensor 104. Thermometers 1110 located atcold inlets of the vessel allow for useful volume of water delivered toend users to be determined and thermometers 1110 located at hot outletsallows monitoring of potentially unsanitary exposures to water.

The circuits comprising the thermocline sensors 104 and thermometer(s)1140, as shown in FIGS. 11 and 12, are arranged such that thethermocline sensor 104 and thermometer(s) 1110 have a shared outputterminal 1150. The shared output has no more than two or three (notshown) electrical terminals that are used to obtain an output from thethermocline sensor 104 and thermometer(s) 1110.

FIG. 13 shows a flow diagram of the combined thermocline sensor 104 andthermometer 1110 circuit under AC/DC operation 1300. In a first step1310, a DC signal is applied across terminals 302, and the output signalfrom the circuit 1100 across output terminals 1150 is monitored. Theoutput voltage, V_(out), from output terminals 1150 is subsequentlyrecorded and, given that R_(s) is known and that no current flowsthrough the thermometer 1110, the resistance across the thermoclinesensor 104, R_(t), can be computed in step 1320. In a following step1330, an AC signal is applied across the circuit 1100 at a frequencythat is far greater than the maximum anticipated value of the inverse ofthe zero time constant of the circuit 1100. The frequency is alsoselected so that it is high enough to avoid temperature related effectson the frequency response of the circuit (i.e. the thermocline sensor104 and thermometer 1110 circuit) when sensing the referencetemperature. The output voltage, V_(out), is recorded and, on the basisof the change in magnitude response of the output voltage in step 1330relative to the output voltage recorded in step 1320, R_(r) is computed1340. Finally, the temperature associated with the computed value ofR_(r) is correlated with R_(t) so that the proximity of the thermoclinewithin the vessel 106 to vessel outlet 118 and/or the remaining useablevolume of water within the vessel 106 is associated with the temperatureto which R_(r) relates 1350. The process of AC/DC operation 1300 is alsoavailable to be used with circuits that have multiple thermometers 1110,as per circuit 1200. Alternatively, a DC signal is used to obtain areading from the temperature sensor 1110 and an AC signal to obtain asignal from the thermocline sensor 104.

The thermometer 1150 is used to calibrate the output of the thermoclinesensor 104, detect unsanitary exposures and, where the measurementprovided by the thermometer is taken close to the vessel inlet, anindication of useful volume of fluid developed downstream of the vessel.For an array of thermometers (as shown in FIG. 12) where the output ofeach thermometer is available to be determined independently, the arrayis used in addition to the thermocline sensor 104 to determine theuseful volume of fluid within the vessel developed downstream of thevessel.

FIG. 14 shows signal processing of the output signal from thethermocline sensor 104 in the form of a flow diagram 1400. Once anoutput signal has been obtained from the thermocline sensor 104 in afirst step 1404, the signal is conditioned such that the useful volumeof fluid within the vessel 106 is accurately derivable, for example byusing numerical integration of TED-detected temperature-dependentparameters; applying a gain and/or bias of the thermocline sensor 104;and applying a wall model and/or model fitting 1408. The signalconditioned in step 1408 is further processed in order to derive theuseful volume of fluid within the vessel 106, for example by using lowpass filters, Savitzky-Golay filters, moving averages and localregression 1412. The output from step 1412 is made available to analgorithm for logging draw events (a “log algorithm”), which logs drawevents that result in the removal of fluid from the vessel 1416. Thelogged draws are displayed to the user 120 and/or recorded 1420, forexample in the form of water usage history, energy consumption and/orthe remaining amount of useable water within the vessel 106. Apredictive model is applied to the information made available to the logalgorithm 1424. For example a Markov model is used to anticipate whenheating of the water within the vessel is required and/or when the waterwithin the vessel will surpass an unsanitary threshold, as unsanitaryexposures tend to coincide with large draw events (as indicated by therate of change of the output from a thermocline sensor 104), for exampleduring shower usage, which is of particular concern due to the addedrisk of inhaling contaminated water that has been aerolised.

The thermocline sensor 104 and controller 100, having the ability todetermine the position of the thermocline in a stratified body of waterwithin a vessel (and thus determine the exergy within the vessel),provide an indication of the level of the thermocline relative to theposition of the vessel outlet 118 (or outlets) and therefore react (e.g.by providing a sanitary hazard flag or scheduling heating of the fluidwithin the vessel) in anticipation of unsanitary draw events from thevessel. The addition of at least one thermometer 1110 provides greaterconfidence of the temperature of fluid at a given position within thevessel, preferably at the vessel outlet 118 or inlet 121. Thereliability of determining the position of the thermocline relative to areference position is thereby improved and the sanitary conditions ofwater at a given position is determinable with a greater degree ofcertainty. The thermometer 1110 also provides a means of calibrating theoutput of the thermocline sensor 104 with respect to a referencetemperature determined from one or more of the thermometers 1110. If thepredictive model determines that user exposure to unsanitary water islikely, a sanitary hazard flag is raised 1428, either as a warningdetectable by the user 120 or as a trigger for a response to preventexposure to unsanitary water. The predictive algorithm also schedulesheating of water if it anticipates that the volume of useful water islikely to be expended 1432. A determination is made at step 1436 as towhether a heat source for heating water in the vessel is currentlyactive—if the heat source is active, then a threshold is logged andcorrected 1440. A disaggregate of the volume of fluid removed from thevessel and the change in sensor output is determined at step 1440 inorder to understand the user's draw activity. If a heating source is on,the threshold rate of the change in the output of the thermocline sensorassociated with a draw event is corrected to recover the true recordingof useful hot water drawn from the vessel. By isolating the effects ofstanding heat loss, and heating of the fluid due to a heating element, amore accurate indication of removal of fluid is provided. A schedule ofactivity of the heating element is used in addition to outputs from thecontroller operating the thermal source to aid decoupling of heating anddraw events. Subsequently, a determination as to the rate of change ofthe available quantity of hot water below a threshold rate 1444 is made.

Otherwise, an uncorrected log threshold is used as a parameter for step1444. If the rate of change of the useful quantity of hot water is notbelow the threshold rate, the process 1444 loops; if not, logging of theuseful quantity of hot water, energy usage and/or thermocline positionbegins 1448 and continues according to a determination of the rate ofchange of the available quantity of water at a useful temperature instep 1452 until this rate falls below the threshold, at which pointlogging of useful volume of fluid, energy usage and/or thermoclineposition ends 1456. Steps 1436-1456 are used to identify draw events onthe basis of the changing output of a thermocline sensor or temperaturearray whose output is aggregated into a single measurement of usefulvolume of water within the vessel 106. Identification of draw events isexploited to record information on historic fluid usage, for examplewith an aim to inform users of their consumption habits; prime a statetransition matrix within a Markov chain to predict the timing and sizeof future draw events for the purposes of scheduling heat sources andflag potentially unsanitary episodes or likely future instances wherethe outlet temperature may drop beneath a sterilising threshold for apathogen, such as Legionella. Additionally, an algorithmic procedure isprovided to condition the output of the thermocline sensor 104 and trackthe changes in state within the vessel which occur due to draw eventsduring operation. Steps 1436-1456 are linked the log usage display step1420, so that the log usage can be presented or indicated to the user.

The controller 100 and/or processor 110 is able to identify distinctmodes of heat loss from the vessel. Draw events from the changing outputof the thermocline sensor 104 with time are identified by sudden changesdetected by the thermocline sensor 104, rather than when the output ofthe thermocline sensor drops gradually as a result of standing heatlosses.

Many domestic hot water systems have an internal heat exchanger throughwhich hot water is extracted. In this example, knowledge of thethermocline position alone is insufficient to resolve the quantity ofuseable hot water in the vessel. In such cases, the temperature at thetop of the vessel remains substantially constant during operation andthe temperature of the outlet of the heat exchanger drops due tostarvation as the thermocline transitions across the extent of the heatexchanger. A function that maps the water temperature gradient withinthe vessel to the availability of energy from a heat exchanger immersedwithin the vessel is provided. For example, for a helical coil, amapping between the coil's height relative to the vertical position inthe vessel, coil diameter and pitch are considered. An algorithm whichmaps the temperature profile within the vessel to the likely output froma heat exchanger for a given flow rate and inlet temperature isprovided. Similarly, an algorithm used in combination with a thermalheat exchanger model and a one-dimensional or two-dimensional vesselstratification model in order to resolve the rate of change in outlettemperature for a given flow rate and inlet temperature is used, whichthen computes useable energy, mass or volume of hot water for a givenuseful temperature reference value. By providing a model of the heatexchanger the output of the thermocline sensor is available to accountfor the influence of the heat exchanger and more therefore allow for amore accurate determination of the useful volume of fluid.

FIG. 15 shows a schematic diagram of a device, for example in the formof a processor 1510, for identifying removal of fluid from the vessel106—a draw event. An input indicative of thermal properties of fluidwithin the vessel is received by the processor 1510 from a sensor 1520,for example the thermocline sensor 104. The processor identifies a drawevent by considering the rate of change of the output from the sensor1520 in a first processing step 1530. A determination is made by theprocessor as to whether the change in output signal is due to removal offluid from the vessel or due to static heat loss from the vessel 1540;if the determination indicates the former cause, the processor outputsan instruction to induce dispatch of energy to a heat source tomanipulate the temperature of the fluid within the vessel 1432.

FIG. 16 shows a schematic diagram of a device, for example in the formof a processor 1610, which receives an output from a sensor 1520 thatdetermines thermal properties of a fluid within the vessel through aconductive barrier, such as the vessel wall 1620. The processor appliesa corrective function to the signal received from the sensor 1520 inorder to account for the thermal effects of the vessel wall and indicatemore accurately the thermal properties of the fluid within the vessel1630. The useful volume of fluid within the vessel is thereforedetermined 1640 more accurately using a sensor that measures thermalproperties of the fluid through a conductive barrier by using theadjusted measure of the thermal properties of the fluid by the processor1610. The vessel 106 and sensor 1520 are shown enveloped by a layer ofthermal insulation 1650.

The vessel 106 described with reference to FIG. 1 is for example animmersion heating tank or a similar installation, with an inlet 121 andan outlet 118 in fluid communication with the vessel content. The vesselcan take other forms, for example a heat exchange vessel or a heat storevessel where a fluid conduit (with an inlet and outlet) is in thermalcommunication, but not fluid communication, with the vessel content; ora vessel such as a kettle where the fluid inlet and outlet are combinedin a single aperture. Common to the vessels is a fluid with atemperature profile extending between a first region and a second regionof the vessel, typically due to a localised thermal source or drain,and/or thermal stratification in the vessel.

In one example, the thermocline sensor 104 is integrated onto a flexiblestrip, such as a strip of composite copper, polymer composite (e.g.Espanex or Kapton) and any of the aforementioned circuitry is availableto be printed onto the flexible strip surface prior to etching in aferric chloride bath. For easy retrofit of the thermocline sensor, aportion of the outer insulation of the vessel 108, as is commonlypresent, is removed and the sensor located in the recess formed from theremoval of the insulation. The circuitry comprising the thermoclinesensor 104 is arranged such that an adhesive layer is appended to thevessel 108 wall surface, thereby allowing a layer of flexible polymerabove the adhesive layer to be in thermal contact with the vessel wall.Above the flexible polymer layer, a layer of copper and/or printedcircuit board trace is present with a layer of electrical components isprovided above therein. An outer insulation layer on the thermoclinesensor arrangement is placed as a final layer. It is therefore envisagedthat thermocline sensors 104 composed on reels of flexible strips ofadhesive tape are manufactured by a continuous method of production. Akit of parts for easy retrofit onto a vessel is therefore available.

In one example the PTC or NTC elements used in the thermocline sensor104 have a non-linear response (e.g. as per a thermistor made of BariumTitanate), in particular around the Curie transition temperature. TheCurie transition temperature is used to provide an integral limit thatdifferentiates between useful and non-useful energy. Advantageously theresponse of a PTC resistor will occur only above a certain thresholdthereby introducing an inherent threshold for judging a usefultemperature.

It will be understood that the present invention has been describedabove purely by way of example, and modifications of detail can be madewithin the scope of the invention.

Each feature disclosed in the description, and (where appropriate) theclaims and drawings may be provided independently or in any appropriatecombination.

Reference numerals appearing in the claims are by way of illustrationonly and shall have no limiting effect on the scope of the claims.

1. A sensor for measuring a temperature profile of a fluid within avessel, the sensor comprising: an array of elements, each element havinga temperature-dependent parameter, the array being capable of deploymentwithin or adjacent the vessel such that the array extends along thevessel for measuring the temperature profile, wherein the arraycomprises a substrate that can be cut to length to determine the numberof elements within the array.
 2. The sensor according to claim 1,wherein the substrate includes a flexible strip.
 3. The sensor accordingto claim 2, wherein the flexible strip includes a flexible circuit. 4.The sensor according to claim 3, wherein the flexible circuit includesan etched or a printed circuit trace.
 4. The sensor according to claim4, wherein the flexible circuit includes a layer of electricalcomponents suitably connected with the circuit trace.
 6. The sensoraccording to claim 2, wherein the flexible strip includes a flexiblepolymer layer.
 6. The sensor according to claim 6, wherein the polymeris a polyimide.
 8. The sensor according to claim 2, wherein the flexiblestrip comprises Espanex or Kapton.
 9. The sensor according to claim 2,wherein the flexible strip includes an adhesive layer for attachment tothe vessel.
 10. The sensor according to claim 2, wherein the flexiblestrip includes an insulation layer.
 11. The sensor according to claim 2,wherein the flexible strip is provided on a reel.
 12. The sensoraccording to claim 2, wherein the flexible strip is manufactured by acontinuous method of production.
 13. The sensor according to claim 1,wherein the substrate includes a shelter.
 14. The sensor according toclaim 13, wherein the shelter is a pipe.
 15. The sensor according toclaim 1, wherein the substrate includes a support.
 16. The sensoraccording to claim 15, wherein the support is a pipe.
 17. The sensoraccording to claim 1, wherein the elements of the array are coupledtogether in parallel.
 18. The sensor according to claim 1, wherein acontroller is calibrated to a substrate cut length.
 19. A fluidtemperature controller comprising a first input for receiving a signalfrom a sensor according to claim 1, and a processor configured tocalculate a total thermal energy of fluid in the vessel based on thesignal, wherein the processor is configured to operate in dependenceupon the number of array elements along the length of the sensor.